US9049935B2 - Control assembly for chair - Google Patents

Control assembly for chair Download PDF

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Publication number
US9049935B2
US9049935B2 US14/029,224 US201314029224A US9049935B2 US 9049935 B2 US9049935 B2 US 9049935B2 US 201314029224 A US201314029224 A US 201314029224A US 9049935 B2 US9049935 B2 US 9049935B2
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Prior art keywords
assembly
support structure
member
biasing
position
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US14/029,224
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US20140077552A1 (en
Inventor
Robert J. Battey
Gary Lee Karsten
Kurt R. Heidmann
Todd T. Andres
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Steelcase Inc
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Steelcase Inc
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Priority to US201261703667P priority Critical
Priority to US201261703659P priority
Priority to US201261703515P priority
Priority to US201261703666P priority
Priority to US201261703677P priority
Priority to US201261703661P priority
Priority to US201261703663P priority
Priority to US29/432,767 priority patent/USD697727S1/en
Priority to US29/432,765 priority patent/USD697726S1/en
Priority to US201361754803P priority
Priority to US14/029,224 priority patent/US9049935B2/en
Application filed by Steelcase Inc filed Critical Steelcase Inc
Assigned to STEELCASE INC reassignment STEELCASE INC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ANDRES, TODD T., BATTEY, ROBERT J., HEIDMANN, KURT R., KARSTEN, GARY
Publication of US20140077552A1 publication Critical patent/US20140077552A1/en
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    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C1/00Chairs adapted for special purposes
    • A47C1/02Reclining or easy chairs
    • A47C1/022Reclining or easy chairs having independently-adjustable supporting parts
    • A47C1/024Reclining or easy chairs having independently-adjustable supporting parts the parts, being the back-rest, or the back-rest and seat unit, having adjustable and lockable inclination
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C1/00Chairs adapted for special purposes
    • A47C1/02Reclining or easy chairs
    • A47C1/022Reclining or easy chairs having independently-adjustable supporting parts
    • A47C1/03Reclining or easy chairs having independently-adjustable supporting parts the parts being arm-rests
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C1/00Chairs adapted for special purposes
    • A47C1/02Reclining or easy chairs
    • A47C1/031Reclining or easy chairs having coupled concurrently adjustable supporting parts
    • A47C1/032Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C1/00Chairs adapted for special purposes
    • A47C1/02Reclining or easy chairs
    • A47C1/031Reclining or easy chairs having coupled concurrently adjustable supporting parts
    • A47C1/032Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest
    • A47C1/03255Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest with a central column, e.g. rocking office chairs
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C1/00Chairs adapted for special purposes
    • A47C1/02Reclining or easy chairs
    • A47C1/031Reclining or easy chairs having coupled concurrently adjustable supporting parts
    • A47C1/032Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest
    • A47C1/03261Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest characterised by elastic means
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C1/00Chairs adapted for special purposes
    • A47C1/02Reclining or easy chairs
    • A47C1/031Reclining or easy chairs having coupled concurrently adjustable supporting parts
    • A47C1/032Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest
    • A47C1/03261Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest characterised by elastic means
    • A47C1/03266Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest characterised by elastic means with adjustable elasticity
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C1/00Chairs adapted for special purposes
    • A47C1/02Reclining or easy chairs
    • A47C1/031Reclining or easy chairs having coupled concurrently adjustable supporting parts
    • A47C1/032Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest
    • A47C1/03261Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest characterised by elastic means
    • A47C1/03272Reclining or easy chairs having coupled concurrently adjustable supporting parts the parts being movably-coupled seat and back-rest characterised by elastic means with coil springs
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C1/00Chairs adapted for special purposes
    • A47C1/14Beach chairs ; Chairs for outdoor use, e.g. chairs for relaxation or sun-tanning
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C3/00Chairs characterised by structural features; Chairs or stools with rotatable or vertically-adjustable seats
    • A47C3/20Chairs or stools with vertically-adjustable seats
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C3/00Chairs characterised by structural features; Chairs or stools with rotatable or vertically-adjustable seats
    • A47C3/20Chairs or stools with vertically-adjustable seats
    • A47C3/30Chairs or stools with vertically-adjustable seats with vertically-acting fluid cylinder
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C31/00Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/02Upholstery attaching means
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C31/00Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/02Upholstery attaching means
    • A47C31/023Upholstery attaching means connecting upholstery to frames, e.g. by hooks, clips, snap fasteners, clamping means or the like
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C5/00Chairs of special materials
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C5/00Chairs of special materials
    • A47C5/12Chairs of special materials of plastics, with or without reinforcement
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/002Chair or stool bases
    • A47C7/004Chair or stool bases for chairs or stools with central column, e.g. office chairs
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/002Chair or stool bases
    • A47C7/006Chair or stool bases with castors
    • A47C7/022
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/02Seat parts
    • A47C7/029Seat parts of non-adjustable shape adapted to a user contour or ergonomic seating positions
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/02Seat parts
    • A47C7/14Seat parts of adjustable shape; elastically mounted ; adaptable to a user contour or ergonomic seating positions
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/02Seat parts
    • A47C7/18Seat parts having foamed material included in cushioning part
    • A47C7/185Seat parts having foamed material included in cushioning part with a stiff, rigid support
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/02Seat parts
    • A47C7/24Upholstered seats
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/36Support for the head or the back
    • A47C7/40Support for the head or the back for the back
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/36Support for the head or the back
    • A47C7/40Support for the head or the back for the back
    • A47C7/44Support for the head or the back for the back with elastically-mounted back-rest or backrest-seat unit in the base frame
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/36Support for the head or the back
    • A47C7/40Support for the head or the back for the back
    • A47C7/44Support for the head or the back for the back with elastically-mounted back-rest or backrest-seat unit in the base frame
    • A47C7/441Support for the head or the back for the back with elastically-mounted back-rest or backrest-seat unit in the base frame with adjustable elasticity
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/36Support for the head or the back
    • A47C7/40Support for the head or the back for the back
    • A47C7/44Support for the head or the back for the back with elastically-mounted back-rest or backrest-seat unit in the base frame
    • A47C7/443Support for the head or the back for the back with elastically-mounted back-rest or backrest-seat unit in the base frame with coil springs
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/36Support for the head or the back
    • A47C7/40Support for the head or the back for the back
    • A47C7/46Support for the head or the back for the back with special, e.g. adjustable, lumbar region support profile; "Ackerblom" profile chairs
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/36Support for the head or the back
    • A47C7/40Support for the head or the back for the back
    • A47C7/46Support for the head or the back for the back with special, e.g. adjustable, lumbar region support profile; "Ackerblom" profile chairs
    • A47C7/462Support for the head or the back for the back with special, e.g. adjustable, lumbar region support profile; "Ackerblom" profile chairs adjustable by mechanical means
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/54Supports for the arms
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B68SADDLERY; UPHOLSTERY
    • B68GMETHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G7/00Making upholstery
    • B68G7/12Other elements specially adapted for fastening, fixing, or finishing, in upholstery work
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/48Upholstered article making
    • Y10T29/481Method
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49826Assembling or joining
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49826Assembling or joining
    • Y10T29/49947Assembling or joining by applying separate fastener

Abstract

A control assembly for a chair including a base structure including a first pivot point and a second pivot point spaced from the first pivot point, and a seat support structure directly pivotably coupled to the base structure for rotation about the first pivot point, a back support structure pivotably coupled to the base structure for rotation about the second pivot point, wherein the back support structure is adapted to move between a first and second position, a control link having a first end operably coupled to the seat support structure, and a second end operably coupled to the back support structure, and a biasing assembly exerting a biasing torque about the second pivot point that biases the back support structure from the second position toward the first position, wherein the biasing torque is adjustable between first and second magnitudes when the back support structure is in the first position.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/703,677, filed on Sep. 20, 2012, entitled “CHAIR ASSEMBLY,” U.S. Provisional Patent Application No. 61/703,667, filed on Sep. 20, 2012, entitled “CHAIR ARM ASSEMBLY,” U.S. Provisional Patent Application No. 61/703,666, filed on Sep. 20, 2012, entitled “CHAIR ASSEMBLY WITH UPHOLSTERY COVERING,” U.S. Provisional Patent Application No. 61/703,515, filed on Sep. 20, 2012, entitled “SPRING ASSEMBLY AND METHOD,” U.S. Provisional Patent Application No. 61/703,663, filed on Sep. 20, 2012, entitled “CHAIR BACK MECHANISM AND CONTROL ASSEMBLY,” U.S. Provisional Patent Application No. 61/703,659, filed on Sep. 20, 2012, entitled “CONTROL ASSEMBLY FOR CHAIR,” U.S. Provisional Patent Application No. 61/703,661 filed on Sep. 20, 2012, entitled “CHAIR ASSEMBLY,” U.S. Provisional Patent Application No. 61/754,803 filed on Jan. 21, 2013, entitled “CHAIR ASSEMBLY WITH UPHOLSTERY COVERING,” U.S. Design patent application No. 29/432,765 filed on Sep. 20, 2012 entitled “CHAIR,” and U.S. Design patent application No. 29/432,767 filed on Sep. 20, 2012, entitled “CHAIR,” the entire disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a control assembly of a chair assembly, and in particular to a control assembly comprising a 4-bar linkage assembly adapted to control a movement of a seat support structure relative to movement of a back support structure.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention is to provide a control assembly for a chair comprising a base structure defining an upper portion having a first pivot point and a lower portion located below the upper portion and having a second pivot point spaced from the first pivot point, wherein the base structure is adapted to attach to a ground-abutting base support structure, and a seat support structure having a forward portion pivotably coupled to the upper portion of the base structure for rotation about the first pivot point and a rearward portion located rearward of the forward portion, and wherein the seat support structure is adapted to support a seated user. The control assembly further comprises a back support structure having a forward portion pivotably coupled to the lower portion of the base structure for rotation about the second pivot point and a rearward portion located rearwardly of the forward portion, wherein the back support structure is adapted to move between a first position and a second position, and a control link having a first end pivotably coupled to the rearward portion of the seat support structure for rotation about a third pivot point, and a second end pivotably coupled to the rearward portion of the back support structure for rotation about a fourth pivot point.

Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure having a first pivot point and a second pivot point spaced from the first pivot point, wherein the base structure is adapted to attach to a ground-abutting base support structure, and a seat support structure directly pivotably coupled to the base structure for rotation about the first pivot point, and wherein the seat support structure is adapted to support a seated user. The control assembly further comprises a back support structure directly pivotably coupled to the base structure for rotation about the second pivot point, wherein the back support structure is adapted to rotate between a first position and a second position, and a control link having a first end operably coupled to the seat support structure, and a second end operably coupled to the back support structure, wherein the control link rotates the seat support structure at a slower rate of rotation than a rate of rotation of the back support structure as the back support structure is rotated between the first and second positions.

Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure defining a first pivot point and a second pivot point spaced from the first pivot point, wherein the base structure is adapted to attach to a ground-abutting base support structure, and a seat support structure pivotably coupled to the first pivot point, wherein the seat support structure is adapted to support a seated user. The control assembly further comprises a back support structure pivotably coupled to the second pivot point, wherein the back support structure is adapted to move between a first position and a second position, and wherein the base structure does not move as the back support structure moves between the first and second positions, and a control link pivotably coupled to the rearward portion of the seat support structure for rotation about a third pivot point, and pivotably coupled to the back support structure for rotation about a fourth pivot point, wherein a distance between the first pivot point and the second pivot point is greater than a distance between the third pivot point and the fourth pivot point.

Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure including a first pivot point and a second pivot point spaced from the first pivot point, wherein the base structure is adapted to attach to a ground-abutting base structure, a seat support structure directly pivotably coupled to the base structure for rotation about the first pivot point, and wherein the seat support structure is adapted to support a seated user, and a back support structure directly pivotably coupled to the base structure for rotation about the second pivot point, wherein the back support structure is adapted to move between a first full-travel position and a second full-travel position opposite the first full-travel position. The control assembly also comprises a control link having a first end operably coupled to the seat support structure, and a second end operably coupled to the back support structure, wherein the control link is adapted to move between a first position and a second position as the back support structure moves between the first full-travel position and a second full-travel position, the control link includes a longitudinally extending axis that is adapted to form a first angle with a seat support surface of the seat support structure when the control link is in the first position and a second angle with the seat support surface of the seat support structure when the control link is in the second position, the first angle is an acute angle, and wherein the axis of the control link does not rotate substantially beyond perpendicular with the seat support surface as the control link moves between the first and second positions.

Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure defining an upper portion and a lower portion located below the upper portion, a seat support structure having a forward portion operably coupled to the base structure and a rearward portion located rearwardly of the forward portion, wherein the seat support structure is adapted to support a seated user, and a back support structure having a forward portion operably coupled to the base structure and a rearward portion located rearwardly of the forward portion, wherein the back support structure is adapted to move between a first position and a second position. The control assembly further comprises a control link having a first end operably coupled to the rearward portion of the seat support structure, and a second end operably coupled to the rearward portion of the back support structure, wherein a select one of the base structure and the control link is fixed for rotation with respect to a ground support surface as the back support is moved between the first and second positions.

Another aspect of the present invention is to provide a control assembly for a chair comprising a base structure including a first pivot point and a second pivot point spaced from the first pivot point, wherein the base structure is adapted to be attached to a ground-abutting base support structure, a seat support structure directly pivotably coupled to the base structure for rotation about the first pivot point, wherein the seat support structure is adapted to support a seated user thereon, and a back support structure directly pivotably coupled to the base structure for rotation about the second pivot point, wherein the back support structure is adapted to move between a first position and a second position. The control assembly also includes a control link having a first end operably coupled to the seat support structure, and a second end operably coupled to the back support structure, and at least one biasing assembly exerting a biasing force torque about the second pivot point that exerts a biasing force against the back support structure that biases the back support structure from the second position towards the first position, wherein the biasing force torque about is adjustable between first and second magnitudes when the back support structure is in the first position, and wherein the second magnitude is greater than the first magnitude.

Yet another aspect of the present invention is to provide a control assembly for a chair comprising a base structure adapted to attach to a ground-abutting base support structure, a seat support structure adapted to couple to the base structure, wherein the seat support structure is adapted to support a seated user thereon, and a back support structure operably coupled to the base structure, wherein the back support structure is adapted to move between a first position and a second position. The control assembly further comprises at least one biasing assembly exerting a biasing force that biases the back support structure from the second position towards the first position, wherein the biasing force is adjustable between first and second magnitudes when the back support structure is in the first position, and wherein the second magnitude is greater than the first magnitude, and an assist feature exerting an assist force on the biasing assembly, thereby reducing the input force required to be applied by the user to adjust the biasing force between the first and second magnitudes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a chair assembly embodying the present invention;

FIG. 2 is a rear perspective view of the chair assembly;

FIG. 3 is a side elevational view of the chair assembly showing the chair assembly in a lowered position and in a raised position in dashed line, and a seat assembly in a retracted position and an extended position in dashed line;

FIG. 4 is a side elevational view of the chair assembly showing the chair assembly in an upright position and in a reclined position in dashed line;

FIG. 5A is an exploded view of the seat assembly;

FIG. 5B is an enlarged perspective view of the chair assembly with a portion of the seat assembly removed to illustrate a spring support assembly;

FIG. 6 is an exploded perspective view of the seat assembly;

FIG. 7 is a top perspective view of the seat assembly;

FIG. 8 is a bottom perspective view of the seat assembly;

FIG. 9 is an exploded bottom perspective view of the cover assembly and the seat assembly;

FIG. 10 is a cross-sectional view of the cover assembly;

FIG. 11 is an exploded perspective view of an alternative embodiment of the seat assembly;

FIG. 11A is an exploded perspective view of another alternative embodiment of the seat assembly;

FIG. 12 is a top perspective view of the alternative embodiment of the seat assembly;

FIG. 13 is a bottom perspective view of the alternative embodiment of the seat assembly;

FIG. 14 is an exploded bottom perspective view of the alternative embodiment of the seat assembly;

FIG. 15 is a top perspective view of a second alternative embodiment of the seat assembly;

FIG. 16 is a cross-sectional view of the second alternative embodiment of the seat assembly taken along the line XVI-XVI, FIG. 15;

FIG. 17 is a cross-sectional view of the second alternative embodiment of the seat assembly taken along the line XVII-XVII, FIG. 15;

FIG. 18 is a front perspective view of a back assembly;

FIG. 19 is a side elevational view of the back assembly;

FIG. 20A is an exploded front perspective view of the back assembly;

FIG. 20B is an exploded rear perspective view of the back assembly;

FIG. 21 is an enlarged perspective view of an area XXI, FIG. 20A;

FIG. 22 is an enlarged perspective view of an area XXII, FIG. 2;

FIG. 23 is a cross-sectional view of an upper back pivot assembly taken along the line XXIII-XXIII, FIG. 18;

FIG. 24A is an exploded rear perspective view of the upper back pivot assembly;

FIG. 24B is an exploded front perspective view of the upper back pivot assembly;

FIG. 25 is an enlarged perspective view of the area XXV, FIG. 20B;

FIG. 26A is an enlarged perspective view of a comfort member and a lumbar assembly;

FIG. 26B is a rear perspective view of the comfort member and the lumbar assembly;

FIG. 27A is a front perspective view of a pawl member;

FIG. 27B is a rear perspective view of the pawl member;

FIG. 28 is a partial cross-sectional perspective view along the line XXVIII-XXVIII, FIG. 26B;

FIG. 29A is a perspective view of the back assembly, wherein a portion of the comfort member is cut away;

FIG. 29B is an enlarged perspective view of a portion of the back assembly;

FIG. 30 is a perspective view of an alternative embodiment of the lumbar assembly;

FIG. 31 is a cross-sectional view of the back assembly and an upholstery assembly;

FIG. 32A-32D are stepped assembly views of the back assembly and the upholstery assembly;

FIG. 33 is an enlarged perspective view of the area XXXIII, FIG. 32A;

FIGS. 34A-34H are a series of back elevational views of a boat cleat and the sequential steps of a drawstring secured thereto;

FIGS. 35G and 35H are alternative sequential steps for securing the drawstring to the boat cleat;

FIG. 36 is an exploded view of an alternative embodiment of the back assembly;

FIG. 37 is a cross-sectional side view of a top portion of the alternative embodiment of the back assembly;

FIG. 38 is a cross-sectional side view of a side portion of the alternative embodiment of the back assembly;

FIG. 39 is a front elevational view of a stay member;

FIG. 40 is a front elevational view of the stay member in an inside-out orientation;

FIG. 41 is a partial front elevational view of the stay member sewn to a cover member;

FIG. 42 is a perspective view of a control input assembly supporting a seat support plate thereon;

FIG. 43 is a perspective view of the control input assembly with certain elements removed to show the interior thereof;

FIG. 44 is an exploded view of the control input assembly;

FIG. 45 is a side elevational view of the control input assembly;

FIG. 46A is a front perspective view of a back support structure;

FIG. 46B is an exploded perspective view of the back support structure;

FIG. 47 is a side elevational view of the chair assembly illustrating multiple pivot points thereof;

FIG. 48 is a side perspective view of the control assembly showing multiple pivot points associated therewith;

FIG. 49 is a cross-sectional view of the chair showing the back in an upright position with the lumbar adjustment set at a neutral setting;

FIG. 50 is a cross-sectional view of the chair showing the back in an upright position with the lumbar portion adjusted to a flat configuration;

FIG. 51 is a cross-sectional view of the chair showing the back reclined with the lumbar adjusted to a neutral position;

FIG. 52 is a cross-sectional view of the chair in a reclined position with the lumbar adjusted to a flat configuration;

FIG. 52A is a cross-sectional view of the chair showing the back reclined with the lumbar portion of the shell set at a maximum curvature;

FIG. 53 is an exploded view of a moment arm shift assembly;

FIG. 54 is a cross-sectional perspective of the moment arm shift assembly taken along the line LIV-LIV, FIG. 43;

FIG. 55 is a top plan view of a plurality of control linkages;

FIG. 56 is an exploded view of a control link assembly;

FIG. 57A is a side perspective view of the control assembly with the moment arm shift in a low tension position and the chair assembly in an upright position;

FIG. 57B is a side perspective view of the control assembly with the moment arm shift in a low tension position and the chair assembly in a reclined position;

FIG. 58A is a side perspective view of the control assembly with the moment arm shift in a high tension position and the chair assembly in an upright position;

FIG. 58B is a side perspective view of the control assembly with the moment arm shift in a high tension position and the chair assembly in a reclined position;

FIG. 59 is a chart of torque vs. amount of recline for low and high tension settings;

FIG. 60 is a perspective view of a direct drive assembly with the seat support plate exploded therefrom;

FIG. 61 is an exploded perspective view of the direct drive assembly;

FIG. 62 is a perspective view of a vertical height control assembly;

FIG. 63 is a perspective view of the vertical height control assembly;

FIG. 64 is a side elevational view of the vertical height control assembly;

FIG. 65 is a cross-sectional perspective view of a first input control assembly taken along the line LXV-LXV, FIG. 42;

FIG. 66A is an exploded perspective view of a control input assembly;

FIG. 66B is an enlarged perspective view of a clutch member of a first control input assembly;

FIG. 66C is an exploded perspective view of the control input assembly;

FIG. 67 is a cross-sectional side elevational view of a variable back control assembly taken along the line LXVII-LXVII, FIG. 42;

FIG. 68 is a perspective view of an arm assembly;

FIG. 69 is an exploded perspective view of the arm assembly;

FIG. 70 is a side elevational view of the arm assembly in an elevated position and a lowered position in dashed line;

FIG. 71 is a partial cross-sectional view of the arm assembly;

FIG. 72 is a top plan view of the chair assembly showing the arm assembly in an in-line position and angled positions in dashed line;

FIG. 73 is a perspective view of an arm assembly including a vertical height adjustment lock;

FIG. 74 is a side elevational view of an arm assembly including a vertical height adjustment lock;

FIG. 75 is a perspective view of an arm assembly including a vertical height adjustment lock;

FIG. 76 is a top plan view of the chair assembly showing an arm rest assembly in an in-line position and rotated positions in dashed line, and in a retracted position and an extended position in dashed line;

FIG. 77 is an exploded perspective view of the arm rest assembly;

FIG. 78 is a cross-sectional view of the arm rest assembly taken along the line LXXVIII-LXXVIII, FIG. 70;

FIG. 79 is a perspective view of a chair assembly;

FIG. 80 is a front elevational view of the chair assembly as shown in FIG. 79;

FIG. 81 is a first side elevational view of the chair assembly as shown in FIG. 79;

FIG. 82 is a second side elevational view of the chair assembly as shown in FIG. 79;

FIG. 83 is a rear side elevational view of the chair assembly as shown in FIG. 79;

FIG. 84 is a top plan view of the chair assembly as shown in FIG. 79;

FIG. 85 is a bottom plan view of the chair assembly as shown in FIG. 79;

FIG. 86 is a perspective view of a chair assembly without an arm rest assembly;

FIG. 87 is a front elevational view of the chair assembly as shown in FIG. 86;

FIG. 88 is a first side elevational view of the chair assembly as shown in FIG. 86;

FIG. 89 is a second side elevational view of the chair assembly as shown in FIG. 86;

FIG. 90 is a rear side elevational view of the chair assembly as shown in FIG. 86;

FIG. 91 is a top plan view of the chair assembly as shown in FIG. 86; and

FIG. 92 is a bottom plan view of the chair assembly as shown in FIG. 86.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. Various elements of the embodiments disclosed herein may be described as being operably coupled to one another, which includes elements either directly or indirectly coupled to one another. Further, the term “chair” as utilized herein encompasses various seating arrangements of office chairs, vehicle seating, home seating, stadium seating, theater seating, and the like.

The reference numeral 10 (FIGS. 1 and 2) generally designates a chair assembly embodying the present invention. In the illustrated example, the chair assembly 10 includes a castered base assembly 12 abutting a supporting floor surface 13, a control or support assembly 14 supported by the castered base assembly 12, a seat assembly 16 and back assembly 18 each operably coupled with the control assembly 14, and a pair of arm assemblies 20. The control assembly 14 (FIG. 3) is operably coupled to the base assembly 12 such that the seat assembly 16, the back assembly 18 and the arm assemblies 20 may be vertically adjusted between a fully lowered position A and a fully raised position B, and pivoted about a vertical axis 21 in a direction 22. The seat assembly 16 is operably coupled to the control assembly 14 such that the seat assembly 16 is longitudinally adjustable with respect to the control assembly 14 between a fully retracted position C and a fully extended position D. The seat assembly 16 (FIG. 4) and the back assembly 18 are operably coupled with the control assembly 14 and with one another such that the back assembly 18 is movable between a fully upright position E and a fully reclined position F, and further such that the seat assembly 16 is movable between a fully upright position G and a fully reclined position H corresponding to the fully upright position E and the fully reclined position F of the back assembly 18, respectively.

The base assembly 12 includes a plurality of pedestal arms 24 radially extending and spaced about a hollow central column 26 that receives a pneumatic cylinder 28 therein. Each pedestal arm 24 is supported above the floor surface 13 by an associated caster assembly 30. Although the base assembly 12 is illustrated as including a multiple-arm pedestal assembly, it is noted that other suitable supporting structures maybe utilized, including but not limited to fixed columns, multiple leg arrangements, vehicle seat support assemblies, stadium seating arrangements, home seating arrangements, theater seating arrangements, and the like.

The seat assembly 16 (FIG. 5A) includes a relatively rigid seat support plate 32 having a forward edge 34, a rearward edge 36, and a pair of C-shaped guide rails 38 defining the side edges of the seat support plate 32 (FIG. 5B) and extending between the forward edge 34 and the rearward edge 36. The seat assembly 16 further includes a flexibly resilient outer seat shell 40 having a pair of upwardly turned side portions 42 and an upwardly turned rear portion 44 that cooperate to form an upwardly disposed generally concave shape, and a forward edge 45. In the illustrated example, the seat shell 40 is comprised of a relatively flexible material such as a thermoplastic elastomer (TPE). In assembly, the outer seat shell 40 is secured and sandwiched between the seat support plate 32 and a plastic, flexibly resilient seat pan 46 which is secured to the seat support plate 32 by a plurality of mechanical fasteners. The seat pan 46 includes a forward edge 48, a rearward edge 50, side edges 52 extending between the forward edge 48 and the rearward edge 50, and a top surface 54 and a bottom surface 56 that cooperate to form an upwardly disposed generally concave shape. In the illustrated example, the seat pan 46 includes a plurality of longitudinally extending slots 58 extending forwardly from the rearward edge 50. The slots 58 cooperate to define a plurality of fingers 60 therebetween, each finger 60 being individually flexibly resilient. The seat pan 46 further includes a plurality of laterally oriented, elongated apertures 62 located proximate the forward edge 48. The apertures 62 cooperate to increase the overall flexibility of the seat pan 46 in the area thereof, and specifically allow a forward portion 64 of the seat pan 46 to flex in a vertical direction 66 with respect to a rearward portion 68 of the seat pan 46, as discussed further below. The seat assembly 16 further includes a foam cushion member 70 having an upper surface 76, and that rests upon the top surface 54 of the seat pan 46 and is cradled within the outer seat shell 40. The seat assembly 16 further includes a fabric seat cover 72 having a forward edge 73, a rearward edge 75, and a pair of side edges 77 extending between the forward edge 73 and rearward edge 75. A spring support assembly 78 (FIGS. 5A and 5B) is secured to the seat assembly 16 and is adapted to flexibly support the forward portion 64 of the seat pan 46 for flexure in the vertical direction 66. In the illustrated example, the spring support assembly 78 includes a support housing 80 comprising a foam and having side portions 82 defining an upwardly concave arcuate shape. The spring support assembly 78 further includes a relatively rigid attachment member 84 that extends laterally between the side portions 82 of the support housing 80 and is located between the support housing 80 and the forward portion 64 of the seat pan 46. A plurality of mechanical fasteners 86 secure the support housing 80 and the attachment member 84 to the forward portion 64 of the seat pan 46. The spring support assembly 78 further includes a pair of cantilever springs 88 each having a distal end 90 received through a corresponding aperture 92 of the attachment member 84, and a proximate end 94 secured to the seat support plate 32 such that the distal end 90 of each cantilever spring 88 may flex in the vertical direction 66. A pair of linear bearings 96 are fixedly attached to the attachment member 84 and aligned with the apertures 92 thereof, such that each linear bearing 96 slidably receives the distal end 90 of a corresponding cantilever spring 88. In operation, the cantilever springs 88 cooperate to allow the forward portion 64 of the seat pan 46, and more generally the entire forward portion of seat assembly 16 to flex in the vertical direction 66 when a seated user rotates forward on the seat assembly 16 and exerts a downward force on the forward edge thereof.

The reference numeral 16 a (FIG. 6) generally designates another embodiment of the seat assembly of the present invention. Since the seat assembly 16 a is similar to the previously described seat assembly 16, similar parts appearing in FIG. 5A and FIGS. 6-10, respectively are represented by the same, corresponding reference numeral, except for the suffix “a” in the numerals of the latter in the illustrated example. The seat assembly 16 a includes a relatively rigid seat support plate 32 a having a forward edge 34 a, a rearward edge 36 a, and a pair of C-shaped guide rails 38 a defining the side edges of the seat support plate 32 a and extending between the forward edge 34 a and the rearward edge 36 a. The seat assembly 16 a further includes a flexibly resilient outer seat shell 40 a (FIGS. 6 and 7) having a pair of upwardly turned side portions 42 a each terminating in a side edge 43 a, a forward edge 45 a, and an upwardly turned rear portion 44 a that terminates in a rear edge 47 a and includes a flap portion 49 a, wherein the side portions 42 a and rear portion 44 a cooperate to form a three-dimensional upwardly disposed generally concave shape. The seat shell 40 a is comprised of a relatively flexible material such as a thermoplastic elastomer (TPE) and is molded as a single integral piece. In assembly, described in further detail below, the outer seat shell 40 a is secured and sandwiched between the seat support plate 32 a and a plastic, flexibly resilient seat pan 46 a which is secured to the seat support plate 32 a by a plurality of mechanical fasteners. The seat pan 46 a includes a forward edge 48 a, a rearward edge 50 a, side edges 52 a extending between the forward edge 48 a and the rearward edge 50 a, a top surface 54 a and a bottom surface 56 a that cooperate to form an upwardly disposed generally concave shape. In the illustrated example, the seat pan 46 a includes a plurality of longitudinally extending slots 58 a extending forwardly from the rearward edge 50 a. The slots 58 a cooperate to define a plurality of fingers 60 a therebetween, each finger 60 a being individually flexibly resilient. The seat pan 46 a further includes a plurality of laterally oriented, elongated apertures 62 a located proximate the forward edge 48 a. The apertures 62 a cooperate to increase the overall flexibility of the seat pan 46 a in the area thereof, and specifically allow a forward portion 64 a of the seat pan 46 a to flex in a vertical direction 66 a with respect to a rearward portion 68 a of the seat pan 46 a, as discussed further below. The seat assembly 16 a further includes a foam cushion member 70 a having an upper surface 76 a, and that rests upon the top surface 54 a of the seat pan 46 a and is cradled within the outer seat shell 40 a. The seat assembly 16 a further includes a fabric seat cover 72 a having a forward edge 73 a, a rearward edge 75 a and a pair of side edges 77 a extending therebetween. The seat assembly 16 a is supported by a spring support assembly 78 a (FIG. 6) that is similar in construction and operation as the previously described spring support assembly 78.

As best illustrated in FIGS. 7 and 8, the flexible resilient seat shell 40 a and the fabric seat cover 72 a cooperate to form an upholstery cover assembly or cover 100 a. Specifically, the side edges 43 a of the seat shell 40 a and the side edges 77 a of the seat cover 72 a, the forward edge 45 a of the seat shell 40 a and the forward edge 73 a of the seat cover 72 a, and the rear edge 47 a of the seat shell 40 a and the rear edge 75 a of the seat cover 72 a are respectively attached to one another to form the cover 100 a and to define an interior space 102 a therein.

The flap portion 49 a of the seat shell 40 a includes a pair of corner edges 104 a each extending along a corner 106 a of the seat shell 40 a located between the rear portion 44 a and respective side portions 42 a, such that the flap portion 49 a is movable between an open position I and a closed position J. In the illustrated example, each corner edge 104 a of the flap portion 49 a includes a plurality of tabs 108 a spaced along the corner edge 104 a and each including an aperture 110 a extending therethrough. The tabs 108 a of the corner edge 104 a are interspaced with a plurality of tabs 112 a spaced along a corner edge 114 a of each side portion 42 a. Each of the tabs 112 a includes an aperture 116 a that extends therethrough. The seat shell 40 a also includes a plurality of integrally-molded coupling tabs 118 a spaced about an inner edge 121 a of the seat shell 40 a and each having a Z-shaped, cross-section configuration.

In assembly, the upholstery cover assembly 100 a (FIG. 9) is constructed from the seat shell 40 a and seat cover 72 a as described above. The seat pan 46 a, the cushion member 70 a and the spring support assembly 78 a are then arranged with respect to one another assembled with the upholstery cover assembly 100 a by positioning the flap 49 a in the open position I, positioning the seat pan 46 a, the cushion member 70 a and spring support assembly 78 a within the interior space 102 a, and then moving the flap 49 a to the closed position J. A pair of quick-connect fasteners 120 a each include a plurality of snap couplers 122 a spaced along the length of an L-shaped body portion 124 a. In assembly, the snap couplers 122 a are extended through the apertures 110 a, 116 a of the tabs 108 a, 112 a, and are snapably received within corresponding apertures 126 a of the seat pan 46 a, thereby securing the corner edges 104 a, 114 a to the seat pan 46 a and the flap portion 49 a in the closed position J.

Further in assembly, the coupling tabs 118 a (FIG. 10) are positioned within corresponding apertures 130 a of the seat pan 46 a, such that the cover assembly 100 a is temporarily secured to the seat pan 46 a, thereby allowing further manipulation of the cover seat assembly 16 a during assembly while maintaining connection and alignment of the cover assembly 100 a with the seat pan 46 a. As used herein, “temporarily securing” is defined as a securing not expected to maintain the securement of the cover assembly 100 a to the seat pan 46 a by itself during normal use of the chair assembly throughout the normal useful life of the chair assembly. The support plate 32 a is then secured to an underside of the seat pan 46 a by a plurality of screws 132 a, thereby sandwiching the coupling tabs 118 a between the support plate 32 a and the seat pan 46 a, and permanently securing the cover assembly 100 a to the seat pan 46 a. As used herein, “permanently securing” is defined as a securing expected to maintain the securement of the cover assembly to the seat pan 46 a during normal use of the chair assembly throughout the normal useful life of the chair assembly.

The reference numeral 16 b (FIG. 11) generally designates another embodiment of the seat assembly. Since the seat assembly 16 b is similar to the previously described seat assemblies 16 and/or seat assembly 16 a, similar parts appearing in FIGS. 5A-10 and FIGS. 11-17 respectively are represented by the same, corresponding reference numeral, except for the suffix “b” in the numerals of the latter. In the illustrated example, the seat assembly 16 b is similar in configuration and construction to the seat assembly 16 and the seat assembly 16 a, with the most notable exception being an alternatively, configured and constructed outer seat shell 40 b and upholstery cover 100 b.

The seat assembly 16 b (FIG. 11) includes a flexibly resilient outer seat shell 40 b having a pair of upwardly turned side portions 42 b each terminating in a side edge 43 b, a forward edge 45 b, and an upwardly turned rear portion 44 b that terminates in a rear edge 47 b, wherein the side portions 42 b and rear portion 44 b cooperate to form a three-dimensional upwardly disposed generally concave shape. The seat shell 40 b is comprised of a relatively flexible material such as a thermoplastic elastomer (TPE) and is molded as a single integral piece. In assembly, described in further detail below, the outer seat shell 40 b is secured and sandwiched between the seat support plate 32 b, a plastic, flexibly resilient seat pan 46 b and a plastic, substantially rigid overlay 51 b, each of which is secured to the seat support plate 32 b by a plurality of mechanical fasteners. The overlay 51 b has an upwardly arcuate shape and includes a rear wall 53 b and a pair of forwardly-extending sidewalls 55 b each including a forward-most edge 57 b, and wherein the rear wall 53 b and sidewalls 55 b cooperate to form an uppermost edge 59 b. The seat pan 46 b includes a forward edge 48 b, a rearward edge 50 b, side edges 52 b extending between the forward edge 48 b and the rearward edge 50 b, a top surface 54 b and a bottom surface 56 b that cooperate to form an upwardly disposed generally concave shape.

As best illustrated in FIGS. 12 and 13, the flexible resilient seat shell 40 b, the fabric seat cover 72 b and the overlay 51 b cooperate to form an upholstery cover assembly or cover 100 b. In the illustrated example, the side edges 43 b of the seat shell 40 b and the side edges 77 b of the seat cover 72 b, the forward edge 45 b of the seat shell 40 b and the forward edge 73 b of the seat cover 72 b, and the rear edge 47 b of the seat shell 40 b and the rear edge 75 b of the seat cover 72 b are respectively attached to one another, such that the seat shell 40 b and the fabric seat cover 72 b cooperate with the overlay 51 b to form the cover 100 b and to define an interior space 102 b therein. The seat shell 40 b also includes a plurality of integrally-molded coupling tabs 118 b spaced about an inner edge 121 b of the seat shell 40 b and each having a Z-shaped, cross-section configuration.

In assembly, the seat shell 40 b (FIG. 14) and seat cover 72 b of the upholstery cover 100 b are coupled to one another as described above. As best illustrated in FIGS. 15 and 16, the side portions 42 b of the seat shell 40 b are coupled to the fabric seat cover 72 b so as to define a corner 79 b therebetween. It is noted that use of both the fabric material of the fabric seat cover 72 b and the TPE of the seat shell 40 b provides a sharp and crisp aesthetic corner angle β of 90° or less while simultaneously providing a soft, resilient deformable feel for the user. The seat pan 46 b, the cushion member 70 b and the spring support assembly 78 b are then arranged with respect to one another and positioned within the interior space 102 b of the cover 100 b. The shell 40 b is then secured to the seat pan 46 b for displacement in a lateral direction by a plurality of integral hook-shaped couplers 123 b spaced about the periphery of the shell 40 b and which engage a downwardly-extending trim portion 125 b extending about the side and rear periphery of the seat pan 46 b. The shell 40 b (FIG. 17) further includes a plurality of Z-shaped couplers 127 b integral with the shell 40 b and received within corresponding apertures 129 b of the seat pan 46 b, thereby temporarily securing the shell 40 b to the seat pan 46 b with respect to vertical displacement.

Further in assembly, the overlay 51 b (FIG. 17) includes a plurality of integrally formed, L-shaped hooks 131 b spaced along the sidewalls 55 b and that slidably engage a corresponding plurality of angled couplers 133 b integrally formed with the seat pan 46 b. Specifically, the hooks 131 b engage the couplers 133 b as the overlay 51 b is slid forwardly with respect to the seat pan 46 b. The overlay 51 b is then secured in place by a pair of screws 135 b that extend through corresponding apertures 137 b of the overlay 51 b and are threadably received within corresponding bosses 139 b of the seat pan 46 b, thereby trapping the couplers 127 b within the apertures 129 b. The support plate 32 b is then secured to an underside of the seat pan 46 b by a plurality of screws 132 b, thereby sandwiching a plurality of spaced coupling tabs 141 b integral with the overlay 51 b between the support plate 32 b and the seat pan 46 b, and permanently securing the cover assembly 100 b to the seat pan 46 b. It is noted that the terms “temporarily securing” and “permanently securing” are previously defined herein.

The reference numeral 16 b′ (FIG. 11A) generally designates another embodiment of the seat assembly. Since the seat assembly 16 b′ is similar to the previously described seat assembly 16 b, similar parts appearing in FIG. 11 and FIG. 11A respectively are represented by the same, corresponding reference numeral, except for the suffix “′” in the numerals of the latter. In the illustrated example, the seat assembly 16 b′ is similar in configuration and construction to the seat assembly 16 b, with the most notable exception being an alternatively configured foam cushion member 70 b′. The cushion member 70 b′ includes a first portion 81 b′ and a second portion 83 b′. In assembly, the first portion 81 b′ of the cushion member 70 b′ is positioned over the seat pan 46 b′. The attachment member 84 b′ is secured to an underside of the seat pan 46 b′ by mechanical fasteners such as screws (not shown). The second portion 83 b′ of the cushion member 70 b′ is then wrapped about the front edge 48 b′ of the seat pan 46 b′ and the attachment member 84 b′, and secured to the attachment member 84 b′ by an adhesive. The combination of the seat pan 46 b′, the cushion member 70 b′ and the attachment member 84 b′ is assembled with the seat support plate 32 b′, to which the spring members 88 b′ are previously attached, and the linear bearing 96 b′ are attached thereto.

The back assembly 18 (FIGS. 18-20B) includes a back frame assembly 200 and a back support assembly 202 supported thereby. The back frame assembly 200 is generally comprised of a substantially rigid material such as metal, and includes a laterally extending top frame portion 204, a laterally extending bottom frame portion 206, and a pair of curved side frame portions 208 extending between the top frame portion 204 and the bottom frame portion 206 and cooperating therewith to define an opening 210 having a relatively large upper dimension 212 and a relatively narrow lower dimension 214.

The back assembly 18 further includes a flexibly resilient, plastic back shell 216 having an upper portion 218, a lower portion 220, a pair of side edges 222 extending between the upper portion 218 and a lower portion 220, a forwardly facing surface 224 and a rearwardly facing surface 226, wherein the width of the upper portion 218 is generally greater than the width of the lower portion 220, and the lower portion 220 is downwardly tapered to generally follow the rear elevational configuration of the frame assembly 200. A lower reinforcement member 228 (FIG. 29A) attaches to hooks 230 of lower portion 220 of back shell 216. The reinforcement member 228 includes a plurality of protrusions 232 that engage a plurality of reinforcement ribs 250 of the back shell 216 to prevent side-to-side movement of lower reinforcement member 228 relative to back shell 216, while the reinforcement member 228 pivotably interconnects back control link 236 to lower portion 220 of back shell 216 at pivot point or axis 590, each as described below.

The back shell 216 also includes a plurality of integrally molded, forwardly and upwardly extending hooks 240 (FIG. 21) spaced about the periphery of the upper portion 218 thereof. An intermediate or lumbar portion 242 is located vertically between the upper portion 218 and the lower portion 220 of the back shell 216, and includes a plurality of laterally extending slots 244 that cooperate to form a plurality of laterally extending ribs 246 located therebetween. The slots 244 cooperate to provide additional flexure to the back shell 216 in the location thereof. Pairings of lateral ribs 246 are coupled by vertically extending ribs 248 integrally formed therewith and located at an approximate lateral midpoint thereof. The vertical ribs 248 function to tie the lateral ribs 246 together and reduce vertical spreading therebetween as the back shell 216 is flexed at the intermediate portion 242 thereof when the back assembly 18 is moved from the upright position E to the reclined position F, as described below. The plurality of laterally-spaced reinforcement ribs 250 extend longitudinally along the vertical length of the back shell 216 between the lower portion 220 and the intermediate portion 242. It is noted that the depth of each of the ribs 250 increases along each of the ribs 250 from the intermediate portion 242 toward the lower portion 220, such that the overall rigidity of the back shell 216 increases along the length of the ribs 250.

The back shell 216 (FIGS. 20A and 20B) further includes a pair of rearwardly extending, integrally molded pivot bosses 252 forming part of an upper back pivot assembly 254. The back pivot assembly 254 (FIGS. 22-24B) includes the pivot bosses 252 of the back shell 216, a pair of shroud members 256 that encompass respective pivot bosses 252, a race member 258, and a mechanical fastening assembly 260. Each pivot boss 252 includes a pair of side walls 262 and a rearwardly-facing concave seating surface 264 having a vertically elongated pivot slot 266 extending therethrough. Each shroud member 256 is shaped so as to closely house the corresponding pivot boss 252, and includes a plurality of side walls 268 corresponding to side walls 262, and a rearwardly-facing concave bearing surface 270 that includes a vertically elongated pivot slot 272 extending therethrough, and which is adapted to align with the slot 266 of a corresponding pivot boss 252. The race member 258 includes a center portion 274 extending laterally along and abutting the top frame portion 204 of the back frame assembly 200, and a pair of arcuately-shaped bearing surfaces 276 located at the ends thereof. Specifically, the center portion 274 includes a first portion 278 and a second portion 280, wherein the first portion 278 abuts a front surface of the top frame portion 204 and the second portion 280 abuts a top surface of the top frame portion 204. Each bearing surface 276 includes an aperture 282 extending therethrough and which aligns with a corresponding boss member 284 integral with the back frame assembly 200.

In assembly, the shroud members 256 are positioned about the corresponding pivot bosses 252 of the back shell 216 and operably pos